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Home/Volkswagen/Passat/Volkswagen Passat B5 рестайлинг (2000-2005)/Repair manual/6 Speed Manual Transmission 01E All Wheel Drive/Function
Contents Section: 6 Speed Manual Transmission 01E All Wheel Drive All sections

Function Volkswagen Passat B5 рестайлинг

6 Speed Manual Transmission 01E All Wheel Drive 23 illustrations ~2189 words

Function

  1. The shift lever must rest in 3rd/4th gear gate when transmission is in neutral.
  1. Actuate clutch.
  2. Select all gears several times. Pay particular attention to the operation of reverse gear lock.
  1. The shift lever must move from reverse gear gate into 3rd/4th gear gate on its own.

If hooking occurs during repeated selection of a gear, the fine adjustment must be performed

  1. Install cover for selector housing and tighten to torque specification.
  2. Install covers and shift knob.
  1. Check whether a coded radio is installed. If this is the case obtain anti-theft coding.
  2. With ignition switched off, disconnect battery Ground (GND) strap.
  3. Remove cover from engine.
  1. Remove sound insulation - arrows -.
  2. Remove sound insulation retainer.

Vehicles with 4-cylinder engine

  1. Remove intermediate pipe of exhaust system --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-255331-S40224648192007053000000) .

Continued for all vehicles

  1. If equipped, remove covers from wheel housings - arrows -.
  1. Remove shielding plate/drive axle on right and left sides - arrows -. The third bolt is not visible in the illustration.
  2. Unbolt left and right drive axles - 1 - from flanges and tie up.
  1. Remove shield - arrows -.
  2. Disconnect driveshaft from transmission --> «Driveshaft, removing and installing»(ref-255341-S36501506522007053000000) .
  3. Then push driveshaft back to limit stop.

Scheme 475

Scheme 475
Scheme 475
  1. Press driveshaft upward against heat shield with a wooden wedge - arrow -.

Scheme 476

Scheme 476
Scheme 476
  1. Remove Engine Speed (RPM) Sensor G28 (if equipped) from top left of transmission housing - arrow -.
  2. Disconnect connector from speedometer sensor.
  3. Disconnect back-up light connector.
  4. Unclip wiring for speedometer and back-up light from transmission.
  1. Unbolt starter and set it aside in engine compartment.
  2. It is not necessary to disconnect starter cable.
  3. Remove lower engine/transmission securing bolts.
  4. Set up transmission jack with transmission support 3282 , adjustment plate 3282/12 for "01E" transmission and support elements as follows
  1. Place adjustment plate 3282/12 on transmission support 3282 (Adjustment plate 3282/12 only fits in one position).
  2. Align arms of transmission support according to holes in adjustment plate.

Scheme 477

Scheme 477
Scheme 477
  1. Bolt in support elements - A - , as shown on adjustment plate.

Scheme 478

Scheme 478
Scheme 478
  1. Place transmission jack under vehicle, with arrow symbol - B - on Adjustment plate 3282/12 pointing to front of vehicle.

Scheme 479

Scheme 479
Scheme 479
  1. Align Adjustment plate 3282/12 parallel to transmission and lock safety supports - arrow - on transmission.

Scheme 480

Scheme 480
Scheme 480
  1. Unfasten left and right transmission supports, complete with transmission mount, from transmission and subframe. Remove bolts - 1 - and - 2 -.
  2. Lower transmission slightly using engine/transmission jack V.A.G 1383A.

Remove selector mechanism from transmission as follows

  1. Unbolt connecting rod - 2 - for selector rod from right side of transmission.
  2. Remove push rod - 1 - by unbolting socket head hex bolt.

Scheme 481

Scheme 481
Scheme 481
  1. Remove nut - 1 - and pull transmission shift lever - 2 - from selector shaft of transmission.
  1. Remove clutch slave cylinder - arrow - and secure with wire without opening line system.

Note. Do not depress clutch pedal.

Scheme 482

Scheme 482
Scheme 482
  1. Remove upper connecting bolts for engine/transmission - arrows -.
  2. If equipped, set aside bracket - 3 - with lines and secure with wire.
  3. Press transmission off alignment sleeves.
  4. Carefully lower transmission, thereby observing clearance at drive axles.

To perform work on the transmission, it must be secured to holding fixture VW 540.

Scheme 483

Scheme 483: Transporting transmission
Scheme 483: Transporting transmission
  1. Insert transmission lift hook T40013 into transmission lifting eye and secure.
  2. Engage hook of shop crane into 4th mounting point - arrow - of transmission lift hook.
  3. Lift transmission with shop crane and transmission lift hook T40013.
  1. Clean input shaft splines and lightly lubricate with grease G 000 100 .

The clutch plate must be able to easily slide back and forth on input shaft.

  1. Check clutch release bearing for wear, replace if necessary.
  1. If plastic ring of release bearing is loose, adhere it back onto bearing race with adhesive AMV 195 KD1 01 .
  2. Three rectangular lugs - arrows - of plastic ring engage into notches of release bearing.
  3. If grooves are deeper than 0.5 mm, release bearing must be replaced.
  4. Check if alignment sleeves for centering engine/transmission are in cylinder block, and install if necessary.
  1. If equipped, make sure that the intermediate plate is correctly positioned on engine.
  2. Lightly coat contact surface for plunger on clutch release lever with copper grease.
  3. Before assembling, use a thread cutter to clean residual locking fluid out of threaded holes of transmission flange shaft for driveshaft.
  4. Set up transmission jack with transmission support 3282 , adjustment plate 3282/12 for "01E" transmission and support elements as follows
  1. Place adjustment plate 3282/12 on transmission support 3282 ( adjustment plate 3282/12 only fits in one position).
  2. Align arms of transmission support according to holes in adjustment plate.
  1. Bolt in support elements - A - , as shown on adjustment plate 3282/12.
  1. Place transmission onto transmission jack.
  2. Align adjustment plate 3282/12 and transmission parallel to one another.
  1. Lock safety support - arrow - on transmission.
  1. Set transmission jack under vehicle, arrow symbol - B - ( --> Bolt in support elements under «Transmission, removing and installing (vehicles with 4 and 6-cyl. engine)»(ref-255341-S31347629752007053000000) --> (Scheme 479) ) on adjustment plate 3282/12 points to front of vehicle.
  2. Install transmission, observing clearance at drive axles.
  3. If equipped, push bracket - 3 - with lines onto engine/transmission securing bolt.
  4. Tighten top engine/transmission connecting bolts to torque specification, Table.
  1. Install slave cylinder with bracket for line/hose assembly and fasten bolt - arrow - to torque specification.
  1. Press transmission shift lever - 2 - onto transmission selector shaft.
  2. Tighten nut - 1 -.
  1. The push rod - 1 - is to be fastened to transmission with washers, if equipped.
  2. Fasten connecting rod - 2 - for selector rod to right side of transmission.
  3. Raise transmission using engine/transmission jack V.A.G 1383A until transmission supports can be inserted.
  1. Bolt right and left transmission supports complete with transmission mounts to transmission and subframe (bolts - 1 - and - 2 - --> Right (shown) and left transmission supports to transmission under «Transmission, removing and installing (vehicles with 4 and 6-cyl. engine)»(ref-255341-S31347629752007053000000) ).
  2. Fasten lower bolts for engine/transmission and for starter Table; insert starter --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(ref-255357-S00731330752007053000000) .
  3. Connect back-up light connector.
  4. Connect connector for speedometer sensor.
  1. If equipped, then install Engine Speed (RPM) Sensor G28 to transmission housing - arrow -.
  2. Connect drive axle --> «Driveshaft, removing and installing»(ref-255341-S36501506522007053000000) .
  1. Install shield - arrows -.
  1. Install drive axles - 1 - to flange shafts --> «40 FRONT SUSPENSION»(ref-255349-S18466171542007053000000) .
  2. Install shielding plate/drive axle on right and left sides - arrows -. The third bolt is not visible in illustration --> «40 FRONT SUSPENSION»(ref-255349-S18466171542007053000000) .
  3. Install liners in wheel housings.
  4. Install front exhaust pipe with catalytic converter --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-255331-S40224648192007053000000) .
  1. Check gear oil --> «Transmission oil, checking»(ref-255341-S00851223042007053000000) .
  1. Install sound insulation - arrows -.
  2. Install engine cover.
  3. Connect Ground (GND) strap to battery.
  4. Code radio --> «91 RADIO, TELEPHONE, NAVIGATION, TRIP COMPUTER»(ref-255359-S25491043142007053000000) .
  1. Initialize electrical window regulators, set clock Maintenance.
  2. Adjusting shift mechanism --> «Selector mechanism, adjusting»(ref-255341-S04911084702007053000000) .
  1. Check whether a coded radio is installed. If this is the case obtain anti-theft coding.
  2. With ignition switched off, disconnect battery Ground (GND) strap.
  3. Remove intake air duct, air filter and intake hose --> «24 - MULTIPORT FUEL INJECTION (MFI)»(ref-255331-S09915653522007053000000) .
  4. Move lock carrier into service position: --> «50 BODY, FRONT»(ref-255352-S40424905372007053000000)

Scheme 484

Scheme 484
Scheme 484
  1. Unclip connectors - arrows - from retainer.
  2. Pull connector off from coolant expansion tank.
  3. Unbolt coolant expansion tank and lay aside. Do not open cooling system.
  4. Remove oil filler neck from engine.

Scheme 485

Scheme 485
Scheme 485
  1. Install engine support bridge 10-222 A in conjunction with bracket for engine 10-222 A/1 and adapter 10-222 A/18.
  2. The longer side of adapter 10-222 A/18 faces toward front end.
  3. Secure third spindle 10-222 A/10 to rear left lifting eye of engine using additional hooks 10-222 A/2.
  4. Hook second additional hook 10-222 A/2 in right rear lifting eye of engine.

Scheme 486

Scheme 486
Scheme 486

If necessary, use Motor Transport Loop T40016

  1. Pretension engine/transmission assembly on spindles.
  2. Loosen wheel bolts.
  3. Raise vehicle.
  4. Remove front wheels.
  1. Remove sound insulation - arrows -.
  2. Remove sound insulation retainer.
  3. Remove front exhaust pipes --> «26 - EXHAUST SYSTEM, EMISSION CONTROLS»(ref-255331-S40224648192007053000000) .
  1. Remove shielding plate/drive axle on right and left sides - arrows -. The third bolt is not visible in illustration.
  2. Unbolt left and right drive axles - 1 - from flanges and tie up.
  1. Remove shield - arrows -.
  2. Disconnect driveshaft from transmission --> «Driveshaft, removing and installing»(ref-255341-S36501506522007053000000) .
  3. Push driveshaft back to limit stop.
  1. Press driveshaft upward against heat shield with a wooden wedge - arrow -.
  1. Then remove Engine Speed (RPM) Sensor G28 from top left of transmission housing - arrow -.
  2. Pull off connector from speedometer sensor.
  3. Disconnect back-up light connector.
  4. Unclip wires for speedometer, oxygen sensor and reverse light from transmission.

Scheme 487

Scheme 487
Scheme 487
  1. Remove bolts - arrows - and remove torque support stop - 1 -.

Scheme 488

Scheme 488
Scheme 488
  1. Mark installation position (Pos. - 1 - ) of both engine mounts from below.
  2. Remove nuts - 1 - at bottom on left and right engine mounts.
  3. Remove wiring harness bracket from right engine console.
  4. Disconnect vacuum lines from engine mounts, unclip line from subframe and tie off lines to side.
  1. Remove bolts - 2 - from transmission mount/subframe.

Scheme 489

Scheme 489
Scheme 489
  1. Unclip retaining clamp for coupling rod - 1 - of Left Front Level Control System Sensor G78 from left front control arm - 2 -.

Scheme 490

Scheme 490
Scheme 490
  1. Check on both sides of vehicle, using testing mandrels 3393 , that holes - 1 - and - 2 - are aligned.

If this is not the case, axle alignment must be carried out after tightening of subframe.

Hole - 3 - is not applicable here.

Scheme 491

Scheme 491
Scheme 491
  1. Place engine/transmission jack V.A.G 1383 A with V A G 1359/2 under subframe and apply light pressure.

A - Wooden support

  1. Remove bolts - 1 - and - 2 - at rear of subframe on both sides of vehicle.
  2. Lower subframe slightly using engine/transmission jack V.A.G 1383A.
  3. The bolts of the push rod - 1 - and connecting rod - 2 - must be accessible.

Remove selector mechanism from transmission as follows

  1. Unbolt connecting rod - 2 - for selector rod from right side of transmission.
  2. Remove push rod - 1 - by unbolting socket head hex bolt.
  1. Remove nut - 1 - and pull transmission shift lever - 2 - from selector shaft of transmission.
  2. Remove engine/transmission jack V.A.G 1383 A from under subframe.

Scheme 492

Scheme 492
Scheme 492
  1. Remove bolts - A - at front of subframe on both sides of vehicle.
  2. Remove bolts - B - (2 on each side of vehicle).
  3. Place drip tray V.A.G 1306 underneath.

Scheme 493

Scheme 493
Scheme 493
  1. Remove oil pressure line bracket - arrow - from engine.
  2. Separate oil pressure lines - A - and - B -.

Scheme 494

Scheme 494
Scheme 494
  1. Remove bolt - arrow 1 - from final drive cover.
  2. Remove bolt for oil pressure lines - arrow 2 - on transmission and pull out sideways.

Scheme 495

Scheme 495
Scheme 495
  1. Unfasten oil pressure lines on transmission - arrows - , seal holes with sealing plugs.
  2. Remove oil pressure lines --> «Oil pressure lines, removing and installing»(ref-255341-S23310630622007053000000) .
  3. Remove lower engine/transmission connecting bolts from engine side.
  1. Using spindles, lower engine/transmission assembly approx. 4 rotations.
  1. Remove - arrow 2 - clutch slave cylinder with heat shield - arrow 1 - and secure with wire without opening line system.

Note. Do not depress clutch pedal.

  1. Set up transmission jack with transmission support 3282 , adjustment plate 3282/12 for "01E" transmission and support elements as follows
  2. Place adjustment plate 3282/12 on transmission support 3282 ( adjustment plate 3282/12 only fits in one position).
  3. Align arms of transmission support to correspond with holes in adjustment plate 3282/12.
  1. Screw in support elements - A - , as shown on adjustment plate 3282/12.
  1. Place transmission jack under vehicle, with arrow symbol - B - (illustration above) on adjustment plate 3282/12 pointing to front of vehicle.
  1. Align adjustment plate 3282/12 parallel to transmission and lock the safety supports - arrow - on transmission.

Scheme 496

Scheme 496
Scheme 496
  1. Remove upper engine/transmission connecting bolts - arrows -.
  2. The bolt - arrow A - can be unscrewed, but not pulled out. Be aware of this for reinstallation.
  3. Set bracket - 1 - with lines aside and secure it with wire.
  4. Remove upper bolt at starter - arrow B -.
  1. Remove nut - arrow C - from lower bolt of starter - arrow D -.

On some vehicles, the nut - arrow C - faces toward starter.

  1. The bolt and nut must then be reinstalled the same way.
  2. Remove connecting bolt for engine/transmission - arrow E -.
  3. Press transmission off from alignment sleeves.

Scheme 497

Scheme 497
Scheme 497
  1. Guide transmission off parallel from engine until lower bolt - A - of starter is no longer in hole of transmission - arrow -.
  2. When doing this, note engine/transmission connecting bolt in vicinity of right catalytic converter --> Remove upper engine/transmission connecting bolts under «Removing»(ref-255341-S27904501502007053000000), --> see scheme 190, - arrow A -.
  3. Lower transmission carefully, making sure there is sufficient clearance to drive axles, driveshaft and subframe.

To perform work on transmission, it must be secured to holding fixture VW 540.